Why Ford, and why such a specific year(s)?
I was originally looking at a Duramax (LB7) which would be from 01-03. Problem with the LB7 is the injectors fail, and it's $3000+ to replace all of them (with new injectors). And, they haven't actually figured out the exact problem and provided a permanent fix. So, it's multiple injector replacements over the life of ownership. In ten years, that may be 2 times, at least.
https://www.dieselogic.com/blog/lb7-diesel-fuel-injector said:
Considering that the LB7’s injector problems have been well-documented, GM responded by extending its original injector warranty to 7 years or 200,000 miles. However, a replacement injector’s lifespan is unpredictable. They may give you just 70,000 miles or even upwards of 200,000. However, on average, a replacement injector will last you between 80,000 to 100,000 miles.
Also the dashes on the early GMT800s are just as bad as the GMT400s, so that means shelling out $1000 for an uncracked replacement dash (once sourced).
I started researching other diesels. Dodge's interior build quality is the worst of all, so wrote off Dodge.
Ford's dashes are the best of the three — not uncommon to find an uncracked dash. 2003 was the last year of the 7.3L Power Stroke before Ford introduced the 6.0L Power Stroke mid-year. The injectors in the 7.3L (and maybe later models) have technology designed by Caterpillar; they are very robust and well designed. So, no need to worry about frequent injector replacements if the engine is maintained (i.e., oil changes, fuel filter changes, etc.).
The 2003 7.3L was the last year before EGR was introduced [at least in non-CA emissions 7.3Ls]. I don't want any emissions equipment, such as EGR, DPF. A catalytic converter is okay, as I can remove it without causing a CEL on the 7.3L (no pre and post-cat oxygen sensors, so the computer is unaware of a missing catalytic converter).
7.3L Power Stroke is one of the best engines ever made. Hands down. And Ford is the best selling truck in America for a reason. Don't get me wrong. I love my K2500 and will keep it. If I were looking into a truck with gasoline engine, I don't think I'd be looking into Ford. Would probably be going with another GM.
Just want to rebuild a diesel and I personally think the 2002-2003 Ford 7.3L is the best American diesel truck ever made. I would not completely rule out a 2000-2001, but I would like latest year as possible as they tend to have more options and less problems. With any model vehicle, the earliest years generally have more problems and less options than the later years.
By the way, it's not just about the dash and engine alone. It's total build quality. (Admittedly, the 4R100 transmission isn't as good as the 4L80-E. I'm not averse to driving the ZF-6 manual though.)